Method and apparatus for forming cartons



R. GUYER METHOD AND APPARATUS FOR FORMING CARTONS 4 Sheets-Shee Filed NGV. 6, 194A My i950 R. @WER 251mm.

METHOD .AND APPARATUS FOR FORMING CARTONS Filed Nov. 6, 1944 4; Sheeis-Sheet 2 .57 .53 55 @f 44 @j 16 55 s 5f 2./// 5g/U a I r l s i Patented July 25, 1950 METHOD AND APPARATUS FOR. FORMNG CARTONS Reynolds Guyer, St. Paul, Minn., -assignor to Waldorf Paper vProducts Company,

St. Paul, VMinn.,

a corporation of Minnesota Application November e, 1944, serial No. 562,124

16 Ciaims.

.My invention relates to an improvement in method and apparatus for forming a carton, wherein it is .desired to produce a set up carton in a simple and eiicient manner.

It is the object oi the present invention to pro-- vide a carton blank in at form and to form this carton into tray formation with four rectangu larly arranged side walls upstanding and connected together in a single plunger operation. The carton blank may accordingly be ed into the carton forming apparatus in flat form. The plunger then forces lthe blank into the carton forming apparatus, and this apparatus automatically iolds four carton side walls upwardly from the bottom panel and connects these sides together.

A 'feature of the present invention lies in the provision of a carton having a bottom panel and four vside wall panels foldably connected thereto, and in providing locking tabs on two i the side walls designed to engage in cooperating slots on the remaining side Walls. During the folding operation of the side walls the lockingr tabs are automatically inserted into their respective slots, thus producing a locked carton in asingle operation.

A feature of the present invention resides in providing a carton 'with locking tabs on two opposed side walls which are designed rto engage in cooperating slots on the remaining opposed side walls and to engage the 'locking tabs in their respective 'slots by folding the carton walls bearing the locking tabs beyond an upright position. This folding operation is accomplished while a plunger is positioned within the box and the side walls supporting the locking tabs are returned to their normal upright vposition by withdrawal of the plunger from the interiorfof thecarton.

A further `feature of the present invention lies in the provision of a vcarton of the v'type descrilfi'ed which is equipped with a liner ypreferably of moisture-proof material such as cellophane or the like; This lineris not coeextensive with the side walls, but projects upwardly from certain of the side walls in folded positionoi the carton s0 that these upwardlyeXtend-ing liner portions may be folded over the contents of the carton after the same has been `fil-led. As -a result materials such as vegetables fand the like to be frozen may be inserted within the carton and the carton may then be closed, the upwardly projecting ypor-tions of the moistureproof :liner overlying ,the top of the contentsso-as-tocornpletely encircle thevcontents when the-cartoniisclosed..

A further feature of the .present invention resides -n the attachment of `a nioistureproof liner lto the surface of a cartonand the forming ofthe carton with its attached linerinto an upright tray, the upright 'walls of ywhichare attached together while the .carton is folded into tray formation. The iiat liner sheet is folded to :form a water-proof bag into which the contents of the carton 'may be poured.

A vfurther feature of the present invention llies in the Vmethod of plunging a carton blank into fa carton forming mechanism by means of a plunger which expands in width when pressure is applied thereby against the carton. The plunger is equipped Iwith a resilient blade or hinged blade which normally is of predetermined width, but which expands in effective 'width Vvwhen pressure is applied thereupon.

These and other 'objects and novel `features o`f my `invention will be lmore clearly and fully -set forth Vin the following sp'e'cicationfand claims.'

In the' drawings forming apart of my specification:

Figure 1 is a diagrammatic View .showing the carton blank.

Figure 2showsthe blank of Figure 1 in'partially -set up form. r

Figure 3 shows 'the blank vof Figure 1 when the setting up operation 'has been completed. 'H Figure 4 is a perspective View 'of a carton forming mechanism.

Figure '5 is an elevational nis'm shown in Figure 4,

Figure 6 shows the mechanism of Figure 4 with a `carton blank resting inposition thereon ready for the forming operation. Y

Figure 7 is a view similar to Figure 6 showing thel forming operation partially completed.

Figure 8 is an elevational View showing a subsequent step in .the carton `forming operation.

Figure 9 shows the next step in the carton forming operation, Figure 9 being a sectional View through the carton and forming apparatus.

Figure 10 shows the nal step in the formation ofthe carton. e,

The carton blank A illustrated in Figure 1 of the .drawings includes a front panel il?, a bottom panel I l a rear wall panel l2 and a top panel I'3 connected along parallel Told lines i4, i5, and I6. A front closing iiap Vi is connected to the top panel i3 along the fold line I9. The closing flap His provided with aprojecting tab 2!! which may be accommodated,v in the slot 2i in the 'front panel Il). I

The carton blank is scored along parallel fold lines 22 Aand 23 which separatethe various lpanels view of the mechadescribed from their` respective side panels and closing flaps.

Side wall panels 24 and 25 are secured to the bottom panel II. These side wall panels 24 and 25 are held in upright position in erected condition of the box by locking tabs secured to the front and rear panels |D and I2. Locking panels 26 and 21 are secured to the panels I0 and I2 along the fold line 22. Similar locking tabs or flaps 29 and 33 are connected to the panels |0 and I2 along the fold line 23. These locking tabs are adapted to engage into a slot 3| or 32 in the side walls 24 or 25 respectively.

The locking tabs or naps are all of substantially similar shape. The flaps extend diagonally along lines 33 and terminate in rounded projections 34. These rounded projections extend into the slots 3| and 32 in the manner disclosed.

The tabs or naps 26 and 29 are provided with projecting flaps 35 and 31 secured thereto along aligned fold lines 39 and 40. These flaps 35 and 31 Vproject beyond the ends of the blank but dove tail with the projecting flap portions I1 and 20 of the next adjacent blank. This permits a considerable number of blanks to be cut from a single sheet of material.

The side edges of the flaps 24 and 25 do not extend vertically in upright position of these panels. The flaps 24 and 25 taper from a largest dimension along the fold lines 22 and 23 to a narrower edge at their extremity. This tapering of the flaps 24 and 25 permits the folding of the frontv and rear walls I and I2 beyond vertical position, as will be later described.

The top panel I3 is provided with opposed side locking flaps 4I and 42 which are the full length ofthe panel I3 at the fold lines 22 and 23, but which are considerably narrower in their outer extremity so as to readily t into the slots 3| and 32 when the box is closed. A front locking flap I1 bearing the locking projection 20 has been previously described -to t into the slot 2|. In order to provide a liner for the carton A, a sheet of `moistureproof material such as cellophane or the like is secured to one surface of the sheet. The cellophane preferably extends to the ends of the projecting flaps 35 and 31, these flaps extending to the corners of the cellophane sheet. The sheet of cellophane is also secured to the locking tabs or flaps 26, 21, 29 andA 30, the attachment of the cellophane to these naps being limited to the area bounded by the diagonal line 33, the adjacent fold line 22 or 23, the adjoining straight edge of the flap. The cellophane. may also be attached to the flaps 4| and 42 and to the flaps 24 and 25 outwardly of the slots 3| and 32. The end of the cellophane sheet opposite the end connected to the projecting tabs 35 and 31 is adjacent the ilaps 4| and 42 and may be covered thereby in preferred form of the construction.

In the formation of the carton I employ an apparatus best illustrated in Figures 4 and 5 of the drawings. The mechanism illustrated is typical of a type of device which will serve the intended purpose. I provide a base 43 having a pair of angular guides 44 mounted thereupon to project upwardly therefrom. The guides 44 are held in place by any suitable means such as screws or bolts 45 extending through slots 46 in the base portions oi' the angular guides. The guides 44 are intended merely to hold the carton blank in proper relation relative to the forming apparatus.

Two pairs of spaced springs 41 are secured 4 I to the base 43 by any suitable means such as bolts or screws 49. The springs of each pair are in spaced parallel relation and are opposed to the spaced springs of the other pair. A forming block 55 is supported by each pair of springs 41, each block having substantially parallel vertical upright outer and inner walls 5| and 52, a substantially horizontally extending top wall 53 and an angularly extending bottom wall 54. The bottom wall 54 extends at the same angle from the base as the unattached ends of the springs 41, as best illustrated in Figure 5 of the drawings, the springs 41 extending beyond the inner Walls 52 of the blocks 5i). Each of the blocks 50 is provided with an inclined or beveled surface 55 connecting the vertical inner wall 52 to the top wall 53. This beveled or inclined edge 55 assists in the folding of the front and rear walls I9 and I2 respectively of the carton blank A.

A pair of L-shaped attachments 56 are secured to each of the blocks 5|] as best illustrated in Fig-4 ure 4 of the drawings. These L-shaped blocks 55 include an arm 51 which overlaps the rear surface of the block 50, or preferably engages in a notch in the rear surface of the block 55 as shown. Slots are provided in the arms 51, these slots being indicated by the numeral 5S. Studs extend through the slots 51 and wing nuts 6l! are provided on these studs. By tightening the wing nuts 6|! the attachments '55 may be held in desired adjustment relative to the block 5U.

The attachments 55 also include ends 5| which extend at right angles to the arms 51. These arms or ends 5| are notched or rounded along the inner and upper edges at 62, these notches 62 tending to fold the various locking tabs into engagementwith their respective slots. Angular supports 63 secured to and projecting upwardly from the base 43 engage the carton flaps 24 and 25 outwardly of the slots 3| and 32, tending to open these slots 3| and 32 as the carton blank is forced into the carton forming mechanism designated in general by the letter B.

As illustrated in Figure 6 of th'e drawings a I plunger 64 operated by any suitable plunger rod 65 is arranged to press down upon the carton blank A while the same is resting upon the carton forming mechanism B. The plunger 64 is of a size slightly smaller in external dimension than the interior of the carton in set up position. The undersurface of the plunger 54 is of substantially similar area as the carton bottom panel A leaf spring 65 is centrally secured to the undersurface of the plunger 64 and is spaced somef what from this undersurface of the plunger along opposite edges 61 of the spring. This leaf spring is slightly wider than the undersur'face of the plunger 64 when flattened out, but is normally conned within the dimensions of the bottom of the plunger in the bent formation illustrated in Figure 6.

In the operation of forming the carton A into a set up box as illustrated in Figure 3 of the drawings, the carton blank is rst rested upon the forming mechanism B as illustrated in Figure 6 of the drawings, the blank being held in place by suitable guides such as the guides 44. The plunger |54 is then depressed, the leaf spring 6B engaging the carton bottom panel II near opposed edges thereof. DoWnWard pressure upon the plunger causes the front and rear walls I0 and I2 to fold upwardly along the fold lines I4 and I5, as the walls IU and I2 are supported by the blocks 50 while thefbottom .panel :tl .of .the .carton -isfreeiz 6.3. The ilaps .2.4 and .25 fold along j'the parallelA fold lines 22 and 23.

Figure ,7 of the .drawings `shows the carton in partially formed lposition ywith the .carton apsl or. side .walls 124 :and .25 ifolded agains'tzthe ends .of

the plunger 64 land the frontand rear panels Iii and 1.2 partially `folded condition. The beveled edges 55 .of the lblocks .50 permit a somewhat slower ioldingof the front and .rear Walls Igil and I2 while the unbeveled ends-of the .attachment elements :6l fold theilaps 24 and .-25 :almost `irnmediately ,when thefcarton blanktis pushed downwardly.

noted in Figure .7 of the ,drawings the looking tabs 126, 2, 29 and 39 are .swung toward :the side @wall panels y2li :and 25 'engaging into the slots 3| and 32 therein. The lengthof these slots and the tendency'for the .portion `of the paper beneath the .sslots :to return `,to yl'lorizontal `or at .condition produces an outward bowing .ofthe material beneath-the slots so as `toprovide -an easy `means of entry .fior ythe various locking tabs.

From the position shown -in Figure vrnof .the drawings theoarton moves into the positionshown in vFigure :8 thereof. In this position thetront and rear `Walls yHl and l2 .of ythe rcarton extend vertically V.and the locking tabs are at least y-partially inserted into the slots 3| .and 132. yHowever, to insure the proper locking `of these tabs in the Vrespective slotsthe front and rear lcarton walls 'l0 a-nd I2 are `folded Abeyond vertical -position into the--positionfshown in ,Figure19- Downward `pressu-reof vthe lplunger' .'54 causes fthe bottom of the carton toengage against ithe inwardly projecting ends of thesprings 41, thus -bending the springs-andca-using -the blocks 5,0 'to ftilt -inwardly, causing the front and rearwaglls wand l2' of the cartonto fold against the taperedwallsof the. plunger 64. 'This pivoting of fthe front and rear walls beyond vertical position -is :made possible by the beveling offthe1wallipanels-or'flaps 24 and 25 at 69 and IIJ respectively. f

With the carton walls `pivoted into ;:the position shown in v'li'igure 9, yit is only necessary -to l,swing the-carton wallsback into upright position. This actionis-obtained-by the removal oftheplunger 6!! from `within the carton. When 'the .plunger E4 is moved upwardly the pressure v upon the springsv 4l :is released .and the lblocks 50 returned into-their normal .upright position. The leaf spring 6.6 alsoreturns v'tofits normal shape. The plungerd .may then --be .pulled vertically ,from thecarton, .the natural `tendency of 'the carton to return -to I=lat conditionoausing the awalls :to-

return to vertical position asillustrated in Figure 3 of the drawings.

When the plunger 64 hasbeen removedit-will be noted that a carton has-been completed-with uprightside and end walls and'with aliner of cellophane or other -material lining the walls'and bottom'of the carton. The foldingof the-box in the manner specified creates diagonally :creased corner `folds in the moisture-proof sheet,thereby forming a tray which Awill actually hold water or the like, thus permitting thevcarton to be lled with material havingia relatively high moisture content without danger of leakage asflong as'the carton is not tipped. Thisarrangement .makes the 'carton particularly useful -for containingmaterial such as v'frozen .foods, andthe cartonsimay be readily `held in upright ipositionzuntil after-f the nected thereto, and locking panels on l.celili-inof said iside .wall .panels designed to engage iin slots inthe next adjacent panel, said slots vextending ysubstantie.lly parallel to the fold `lines connecting the vslotted panels to V.said bottom panels, the Vnfiethod consisting in simultaneously bending lupwardly fthe side .Walls of the carton. the bending 1 of the slotted panels opening said slots, `and simultaneously .folding the lockingtabs into engagement with the cooperable .opened slots.

2. iilhe method yof forming a cartonhaving a bottom panel, sidewall panels articulated there.

upon, and closure tabs .ioldably .connected .toy

certain of said .side walls and .engageable in slots in adgavcentside Walls, said slots extending substantially vparallel to? the fold lines I connecting the slotted panels to `said bottom panel, the method consistingof simultaneously bending the side walls to a position -substantially at Vright angles with 4respect to the bottom panel, the

bending of the vslotted panels opening -said slots,` and simultaneously guiding the locking flaps into engagement with the corresponding opened slots.

3. The method :of :forming la carton .havinga bottompanel, side Wall panels articulated thereupon, .fand locking flaps -secured `to certain. of Vsaid side .walls to .engage slots vin others of Vsaid walls, said slots extending :substantially parallel ,to the fold lines -connecting the slotted panels Atosail vbottom panel, the methodconsisting .in folding the side Walls, said .other .of said .side .walls being .foldedinto substantially right angular re-.

lationship vwith .said` bottom .,wall, and Asaidcertain of said `walls being .folded .past 1Vertical position,

the .bending Aof .the slotted slots, simultaneously into .their correspondingopened slots. :and gfolding v.the :latter .two -side walls back into .substantially vertical relation to vthe bottom Wall.

.4. The methodiofoiorming a carton 4having a substantially .rectangular .bottom Ewall panel .and side y.iK/will .panels foldabl-y -connected .thereto along panels .opening said the ,four redges thereof, .two opposed `.side .walls having .locking flaps .foldably ,secured thereto, and thesecond pairof .opposedside walls having slots .therein to accommodate said looking tabs,

said slots .-extendingsubstantially parallel to the.

fold .linesiconnecting ,the slotted panels to said bottom panel, Y,the ,method consisting -in ,folding s aid second .pair of side .Walls into substantially-A vertical .relation relative .to said ...bottom wall, the .bending .of .the slotted .panel-s .opening l.said slots, folding the first mentioned .pair .of side walls upwardly, .and `vsimultaneously guiding lsaid locking tabsintotheopened slots -of -said ,second pair oiside walls.

A.5. The-methodof .forming ya carton Vhaving a substantially rectangular vbottom wall panel :andv

side i Wall panels yfoldably l connected thereto along the ifourfedges thereof, two `opposed side -Walls .guiding the flocking .tabs

and the second pair of opposed side walls having.

slots therein to accommodate said locking tabs, said slots extending substantially parallel to the fold lines connecting the slotted panels to said bottom panel, the method consisting in folding said' second pair of side walls into substantially vertical relation relative to said bottom wall, the bending of the slotted panels opening said slots, folding the first mentioned pair of side walls upwardly, and simultaneously guiding said" locking tabs into the opened slots of said second pair of side walls, said first pair of side walls folding beyond vertical position to `engage said locking tabs in their respective notches.

' 6. The method of forming a carton having a substantially rectangular bottom wall panel and side wall panels foldably connected thereto along the four edges thereof, two opposed side walls having locking flaps foldably secured thereto, and the second pair of opposed side walls having slots therein to accommodate said locking tabs, said slots extending substantially parallel to the fold lines connecting the slotted panels to said bottom panel, the method consisting in folding said-second pair of side walls into substantially vertical relation relative to said bottom wall, the bending of the slotted panels opening said slots, folding the first mentioned pair of side walls upwardly, and simultaneously guiding said locking tabs into the opened slots of said second pair of side walls, said first pair of side walls being folded beyond vertical position to engage said locking flaps in their respective slots, said first side walls then being folded back into substantially right angular relation with said bottom wall.

7. The method of forming a carton having a substantially rectangular -bottom panel, side wall panelsv connected to the edges of said bottom panel, and locking flaps on certain of said side walls engageable in slots in the next adjacent side wall, and a liner secured at intervals to said blank, the method consisting of folding the side walls upwardly from said bottom panel and folding lsaid locking tabs outwardly of the adjacent side wall panels, said liner being secured to said locking naps so as to create diagonal folds in the liner between said locking flaps and the portions of the adjacent walls which they overlie, engaging said locking flaps through slots in the adjacent walls to lie between the inner surface of the wall and the liner, folding the side walls bearing the locking flaps beyond erected position to draw the liner taut, and folding the last mentioned side walls back to erected position.

8, The method of forming a carton having a bottom panel of rectangular shape, side panels connected to the edges of said bottom panels, and locking tabs on certain of said side walls engageable in slots in the next adjacent side wall, and a liner secured at spaced intervals to one surface of the carton blank, the method con- Sistine of folding the side walls relative to the bottom panel, the folding of the side walls creating a diagonal corner tray of said liner, said locking tabs extending over the outer surface of the adjacent wall and portions of the liner being secured to said locking tabs so as to cause the diagonally folded corner portions of the liner to extend between the locking tabs and the outer surface of the adjacent side wall, engaging said locking tabs in their respective slots, folding the side walls bearing the locking flaps beyonderected position to draw the liner taut,

and folding thelast mentioned side walls back to erected position.

9. The method of forming a carton having a bottom panel substantially rectangular in shape,

. Side walls foldably connected to said bottom panel.

and locking flaps on certain of said side walls engageable in slots in the others of said side walls, and a liner secured to said side Walls near the upper extremities thereof, the method consisting in folding the side walls upwardly with respect to the base and folding the locking naps outwardly of the adjacent walls, engaging said locking flaps through their respective slots so that portions of the locking flaps lie between the inner surface of the side wall and the outer surface of the liner, folding the side walls bearing the locking flaps beyond erected position to draw the liner taut, and folding the last mentioned side walls back to erected position.

10. The method of `forming a carton having a bottom wall, side walls foldably connected thereto and locking naps on certain of said side walls engageable in slots'in others of said side walls, the method consisting of supporting the side walls of the carton blank in flat formation of the blank, exerting a downward pressure on the center portion of the blank to fold the side walls relative thereto, and exerting an inward pressure on said certain of said side walls to cause the same to fold past vertical position and simultaneously engaging said locking flaps thereon into said slots.

11. The method of forming a carton consisting of a bottom panel of substantially rectangular shape, side walls foldably connected to the side thereof, and locking flaps on two opposed side walls engageable in cooperable notches in the others of said side walls, the method consisting of supporting the flat carton blank by the side walls thereof, exerting a downward pressure on the unsupported bottom panel to cause the side walls to fold relative thereto, exerting an inward pressure on said two opposed side walls to fold the same past vertical position and simulta- -neously engaging ysaid locking flaps in said cooperable notches.

l2. TheV method of forming a carton having a bottom panel of substantially rectangular shape, side walls foldably connected thereto, and lock- -ing panels on certain of said side walls, the

method consisting of supporting the flat carton blank by the side walls thereof, exerting a force against the unsupported bottom panel to cause the supported side walls to fold relative thereto, and exerting an outward force against the fold lines along two edges of said bottom panel inwardly of the side walls thereon to cause the sameto fold along the proper fold lines.

13. A carton forming apparatus for use in con junction with a carton having a substantially rectangular bottom panel and side walls oldably connected thereto, the apparatus comprising a base, a pair of folding guides pivotally supported in substantially parallel relation to said base, and engageable with two opposed side walls on opposite sides of the bottom panel of a carton, means for forcing the carton against said folding guides to pivot the same and means on said folding guides engageable with the remainingside walls of a carton, to fold the remaining side walls relative to said base.

14. A carton forming' apparatus for use in conjunction with a carton having a substantially rectangular bottom panel and attached sidewall panels, the apparatus comprising a base, a pair of spaced blocks mounted on said base for engagement with two opposed side walls of the carton blank, spring means hingedly connecting said blocks to said base, means for forcing the carton between said blocks to pivot the same, and means on said blocks engageable with the remaining side walls of said carton'to fold the same relative to said base.

15. A carton forming apparatus for use in conjunction with a carton having a substantially rectangular bottom panel and attached side wall panels, and locking tabs foldably connected to two opposed side wall panels and engageable with the remaining side wall panels, the apparatus comprising a base, a pair of spaced blocks mounted on said base for engagement with said two opposed side walls of the carton blank, means hingedly connecting said blocks to said base, folding arms connected to each end of said lblocks and engageable with said locking tabs to fold the same, and means for forcing said carton between said blocks to pivot said blocks.

16. A carton forming apparatus for use in conjunction with a carton having a substantially rectangular bottom panel and attached side wall panels, two opposed side wall panels having locking tabs foldably connected to the ends thereof and the remaining opposed panels having slots therein into which said locking panels may engage, the apparatus comprising a base, means said slots, and means for forcing the carton be- I tween said blocks to pivot the ing arms connected thereto.

REYNOLDS GUYER.

REFERENCES CITED The following references are of record in the ille of this patent:

UNITED STATES PATENTS blocks and the fold- Number Name Date 590,697 Birnie Sept. 28, 1897 926,866 Halbreich July 6, 1909 1,067,253 Inman July 15, 1913 1,212,182 Brooks Jan. 16, 1917 1,534,569 Buttereld Apr. 21, 1925 1,680,615 Hoba Aug. 14, 1928 1,704,175 Coale Mar. 5, 1929 1,757,804 Joplin May 6, 1930 1,906,283 Schulz May 2, 1933 2,135,409 Munn et a1 Nov. 1, 1938 

